It looks like you're enjoying The BBQ Brethren's Forums but haven't created an account yet. Why not take a minute to register for your own free account now? As a member you get free access to all of our forums and posts plus the ability to post your own messages, communicate directly with other members, and much more. Register now!

Already a member? Login at the top of this page to stop seeing this message.

There is only 1 cooking grate in my WSM Mini at 4 " down from the top lip. The grill fits so tightly that I can't take it in and out before and after a cook. So the second grill would be useless for me.

I have two grates in mine. The top grate is 5 inches from the top and the bottom grate rests on the lip where the tamale steamer goes. I drilled holes in the bottom of mine so I place an aluminum pan on a trivet on the bottom that I use as a deflector and/or drip pan. With this set up it gives me 4.5 inches between the grates.

The picture below is with the bottom grate in place. The bolts and nuts you see are mounted from the inside out as I found that the best way to place them to holding the top grate. When I placed the bolt heads on the outside it made it more difficult to emplace and remove the lower grate.

Good luck with your mini WSM project. I love mine. There is a bunch of info posted on these over on the Virtual Bullet site in case you have not already checked it out.

I'd like to keep it full length so I can hang a couple of slabs of ribs in it.
Stability wise I realize it'll be tall vs the narrow width but I also plan on modifying the legs of the kettle to give it a much wider footprint using larger aluminum bar stock.

Yep, it can be done. Several brethren have done this w/ a 15/16 gallon drum. Or just make a mini UDS. Do a search on "15 gallon drum", and you should find multiple examples.

... The grill fits so tightly that I can't take it in and out before and after a cook.

I've made several of these (for myself and the kids) and some of the grates were a real tight fit. To solve that I cut about a 1/4" out of the circumferential wire and my son welded them back together. If I didn't have a son with a welder, I'd trade some 'Q for some help at a local welding shop.

The kids and I built a couple of these using the Vasconia pots.
We put two grates in each one. The bolts for the top grate are 1.5" down from the top lip, and the lower grate bolts are 5.5" down from the top lip.
This config gives 4" of clearance for each of the grates.
We mounted the thermometer just below the bottom grate.